Apparatus and process for two-stage decoding of high-density optical symbols

ABSTRACT

A process comprising computing a histogram of pixel intensity data collected from a digital image of an optically readable symbol including light and dark elements, thresholding the histogram to classify individual pixels as light pixels, dark pixels or gray pixels, thresholding only the portion of the histogram corresponding to gray pixels to re-classify the gray pixels into dark pixels, light pixels or unresolved gray pixels, and heuristically analyzing each string of unresolved gray pixels to determine the elements of the optically readable symbol that created the string of unresolved gray pixels. An apparatus and system to implement the process.

TECHNICAL FIELD

The present invention relates generally to decoding of data encoded inoptically readable symbols and in particular, but not exclusively, to anapparatus and process for two-stage decoding of high-density opticallyreadable symbols such as bar codes.

BACKGROUND

FIG. 1A illustrates, in a highly simplified form, a machine visionsystem 100. The machine vision system 100 can be used to read and decodean optically readable symbol such as bar code 104. A typical bar code ismade up of a series of alternating black (dark) or white (light)elements or bars of various widths. The basic elements of the machinevision system 100 are a focusing element 102 and an image sensor 106. Inoperation of the vision system 100, an optically readable symbol such asa barcode 104 is first positioned in the field of view of the focusingelement 102. The focusing element 102 then focuses an image of thebarcode 104 onto the image sensor 106. The digital image 105 of thebarcode captured by the sensor 106 is then analyzed by other components(not shown) to determine the information encoded in the bar code 104.

FIG. 1B illustrates a phenomenon that occurs with high-density barcodes-that is, bar codes where the widths of the individual light anddark bars begin to get small. As the individual light and dark bars ofthe barcode become narrower, the widths of the individual light and darkelements in the image captured by the sensor 106 get narrower as well.Eventually, the widths XW of the narrowest light bars and the widths XBof the narrowest dark bars start to be of the same order of magnitude asthe widths of individual pixels on the sensor 106. All is well if theimages of the black and white bars substantially coincide with thepixels. Black bar 109, for example, is substantially aligned with apixel on the sensor, and the sensor accurately records that pixel as a“dark” pixel. Similarly, white bar 111 is substantially aligned with apixel, and the sensor accurately records that pixel as a “light” pixel.Black bar 112, however, is different: it is not aligned with a pixel,but instead spans parts of two pixels. Faced with this situation whereeach of two pixels is partially spanned by a black bar 112, such thateach pixel is half black and half white, the sensor records a two-pixel“gray” area 114. Pixel misalignment of multiple bars can lead to largergray areas such as three-pixel gray area 116, which results from bar 108overlapping part of one pixel and bar 110 spanning parts of two pixels.With high-density bar codes, other phenomena besides misalignment canalso result in gray pixels. For example, a string of one or more graypixels might result if one or more of the bars in the image 105 are ofnon-uniform width, which can result from poor printing of the bar code104, damage to the barcode 104, or the like.

Decoders that extract information encoded in the barcode 104 have twotasks. First, based on the image captured by the sensor 106—that is,based on the intensities of the pixels in the image-they mustre-construct the sequence of black and white bars on the original barcode 104. Having correctly re-constructed the original sequence of thebar code, they then analyze the sequence to extract the encodedinformation. Available decoders, however, are usually programmed to dealonly with image pixels that are either dark or light. Faced with stringsof gray pixels, available decoders may not be able to determine thesequence of bars that created the gray areas and may therefore fail toproperly decode a symbol. There is thus a need for an apparatus andmethod for accurately decoding high-density bar codes.

SUMMARY OF THE INVENTION

This application discloses an embodiment of a process comprisingcomputing a histogram of pixel intensity data collected from a digitalimage of an optically readable symbol including light and dark elements,thresholding the histogram to classify individual pixels as lightpixels, dark pixels or gray pixels, thresholding only the portion of thehistogram corresponding to gray pixels to re-classify the gray pixelsinto dark pixels, light pixels or unresolved gray pixels, andheuristically analyzing each string of unresolved gray pixels todetermine the elements of the optically readable symbol that created thestring of unresolved gray pixels. Also disclosed and claimed areembodiments of an apparatus and system to implement the process.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments of the present invention aredescribed with reference to the following figures, wherein likereference numerals refer to like parts throughout the various viewsunless otherwise specified.

FIG. 1A is a schematic drawing illustrating a simplified vision system.

FIG. 1B is a schematic drawing illustrating the alignment of elements ofan image of a barcode with the pixels on an image sensor.

FIG. 2 is a flowchart of an embodiment of a process for decoding ahigh-density bar code according the present invention.

FIGS. 3A and 3B show and embodiment of a process for collecting pixelintensity data from a digital image of an optically readable symbol suchas a barcode.

FIGS. 4A-4C are embodiments of histograms computed from the pixelintensity data collected, in one embodiment, as shown in FIG. 3A.

FIGS. 5A-5C are drawings showing heuristic decoding of unresolvedstrings of gray pixels.

FIG. 6 is a block diagram of an embodiment of an apparatus forimplementing the embodiment of the process shown in FIG. 2.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Embodiments of a system and method for two-stage decoding ofhigh-density optically readable symbols such as bar codes are describedherein. In the following description, numerous specific details aredescribed to provide a thorough understanding of embodiments of theinvention. One skilled in the relevant art will recognize, however, thatthe invention can be practiced without one or more of the specificdetails, or with other methods, components, materials, etc. In otherinstances, well-known structures, materials, or operations are not shownor described in detail but are nonetheless encompassed within the scopeof the invention.

Reference throughout this specification to “one embodiment” or “anembodiment” means that a particular feature, structure, orcharacteristic described in connection with the embodiment is includedin at least one embodiment of the present invention. Thus, appearancesof the phrases “in one embodiment” or “in an embodiment” in thisspecification do not necessarily all refer to the same embodiment.Furthermore, the particular features, structures, or characteristics maybe combined in any suitable manner in one or more embodiments.

FIG. 2 illustrates an embodiment of a two-stage process 200 for decodinghigh-density optically readable symbols such as bar codes. The processstarts at box 202 with some preliminary operations. At box 204, an imageof the high-density bar code is captured by the sensor and at box 206pixel intensity data from the image of the bar code is collected fromthe sensor. One embodiment of a process for collecting pixel intensitydata is described below in connection with FIGS. 3A-3B.

Once the preliminary operations are complete, the first stage ofdecoding begins at box 208, where a histogram is computed from the pixelintensity data collected from the image. At box 210, a thresholdingprocedure is applied to the histogram data to set lower and upperthresholds. At box 212, the upper and lower thresholds are used toclassify each pixel as a light pixel, a dark pixel or a gray pixel.Generally, pixels with intensities below the lower threshold will beclassified as dark pixels, pixels with intensities above the upperthreshold will be classified as light pixels, and pixels withintensities between the lower and upper thresholds will be classified asgray pixels. Next, at box 214, another round of thresholding is appliedonly to the part of the histogram that has been identified as the graypixel area-in other words, to the portion of the histogram between thelower threshold and upper threshold. This second round of thresholdingis designed to take a closer look at the gray pixels to see if, withsome further thresholding, they can be re-classified as light or darkpixels. At box 216, the process identifies dark and light pixels withinthe gray area based on the second thresholding. At box 218, the processchecks whether there are any remaining gray pixels. If there are noremaining gray pixels-meaning that the second thresholding successfullyre-classified all the gray pixels as light or dark-then there-construction of the bar code is complete and there is a successfuldecode at box 220. If any gray pixels remain whose classification isunresolved, the process continues to its second stage, which begins atbox 222. Further details of this first stage of the process arediscussed below in connection with FIGS. 4A-4B.

The second stage of the process attempts to re-construct the barsequence that created the gray areas based on heuristic rules. In oneembodiment the heuristic rules take into account such factors as thewidth in pixels of the gray areas, the bar code elements that bound thegray area, known minimum and maximum bar sizes, and the like. Otherembodiments can, of course, include other factors. At box 222, anystrings of unresolved gray pixels are identified. A string of graypixels comprises one or more adjacent gray pixels; in FIG. 1B, forexample, the two-pixel gray area 114 is a two-pixel string and thethree-pixel area 116 is a three-pixel string.

For each string of unresolved gray pixels identified at box 222, theprocess at box 224 identifies the bar code elements that bound the graystring. At box 226, using the bounding elements and other factors in theheuristic rules, the process identifies the sequence of elements in theoriginal bar code that created the string of gray pixels. At box 228,the process checks whether there are any strings of gray pixels thatcannot be resolved. If there are none, meaning that all strings of graypixels were successfully resolved, then the process continues to box 230and there is a successful decode. If there are any remaining strings ofgray pixels that cannot be resolved, the process ends at box 232 with anunsuccessful decode. Further details of this second stage of the processare discussed below in connection with FIGS. 5A-5C.

FIGS. 3A-3B illustrate an embodiment of a process for collecting pixelintensity data from an image of a barcode. FIG. 3A illustrates theprocessing of an image 302 of a barcode. To obtain pixel intensity data,one or more line scans are conducted across the image 302, beginningfrom the leading edge 304 of the image and ending after the trailingedge 306. As the line scan takes place, the intensity of each pixelalong the line is recorded. In the embodiment shown there are fivescans, each across a different part of the image 302. In otherembodiments, a greater or lesser number of scans can be used, and thescans need not be across different parts of the bar code. FIG. 3Billustrates in tabular form what the resulting data could look like forthe five scan-line process shown in FIG. 3A. The data shown in the tablesummarizes what one would see after some processing of the raw pixelintensity data. For purposes of further analysis, the raw pixelintensity data is what would actually be used, not the L's D's and G'sshown in the table. For each scan line, the scan identifies light (L)areas, dark (D) areas and gray (G) areas of varying pixel length. Thus,the first scan line has identified a 5 pixel light area, followed by a3-pixel gray area, followed by a 1-pixel dark area and so on. When thereare multiple scan lines, the final values used for further analysis canbe determined in various ways. In one embodiment, for example, the finalintensity value used for a given pixel can be the one that occurs mostoften over the five scan lines. In another embodiment, the finalintensity value for the pixel can be the average over the five scanlines.

FIGS. 4A-4C together illustrate the first stage of the two-stagedecoding process. Having collected pixel intensity data, for example asdiscussed above for FIGS. 3A-3B, the pixel intensity data is used tocompute a histogram. For each value of pixel intensity, the histogramcomputes the number, percentage or fraction of pixels having thatparticular intensity. For analysis purposes, the process need onlycompute the necessary data; it is not necessary for the process toconstruct a graphic histogram such as the one shown in the figure. Oncethe histogram data is computed, a thresholding algorithm is applied tothe data to determine an upper intensity threshold I_(L) and a lowerintensity threshold I_(D). In one embodiment, well-known opticalthresholding algorithms such as the bottom-hat algorithm can be used,although in other embodiments other types of algorithms can be appliedas well. With the upper threshold I_(L) and the lower threshold I_(D)computed, the pixels can be initially classified. Pixels with intensitylower than I_(D) are classified as dark pixels, pixels with an intensityhigher than I_(L) are classified as light pixels, and pixels with anintensity between I_(D) and I_(L) are classified as gray pixels.

FIG. 4B illustrates an embodiment of a second round of thresholding thatoccurs after the initial classification of the pixels. The purpose ofthe second round is to take a closer look at the gray pixels to see ifthey can be re-classified as light or dark. In one embodiment,well-known optical thresholding algorithms such as the bottom-hatalgorithm can be used, although in other embodiments other types ofalgorithms can be applied as well. Moreover, this second round ofthresholding need not use the same thresholding algorithm used in thefirst round. In this second round, a thresholding algorithm is appliedonly to that portion of the histogram representing gray pixels, that is,only to pixels with an intensity between I_(D) and I_(L). In theembodiment shown, the distribution of intensities among the gray pixelsis approximately bi-modal, and the second thresholding results in asingle threshold G. With the threshold G established, substantially allof the gray pixels can be re-classified. Gray pixels with intensitylower than G are re-classified as dark pixels, while gray pixels withintensity higher than G are re-classified as light pixels.

FIG. 4C illustrates another embodiment of the second round ofthresholding applied to the gray pixels. This embodiment of the secondthresholding is similar to the second round of thresholding applied inFIG. 4B, but in this embodiment the distribution of intensities of thegray pixels is not bi-modal, meaning that the thresholding will beunable to establish a threshold that will allow re-classification of allthe gray pixels into light or dark pixels. When a threshold cannot beestablished, the gray pixels remain unresolved and the process mustproceed to a heuristic analysis to determine what combination ofelements in the bar code image created the gray pixels. Thedistributions shown in FIGS. 4B and 4C represent the extremes, in whicheither all gray pixels can be re-classified through thresholding (FIG.4B) or none can (FIG. 4C). In other embodiments, the distribution ofintensities of the gray pixels may be such that some of the gray pixelscan be re-classified and some cannot; in such a case, the heuristicanalysis can be applied to any gray pixels that remain unresolved.

FIGS. 5A-5C illustrate embodiments of a second stage of analysis inwhich heuristic processes are used to identify the bar sequence thatcreated any strings of gray pixels that remain unresolved after thefirst stage of analysis. A string of gray pixels comprises one or moreadjacent gray pixels; in FIG. 1B, for example, the two-pixel gray area114 is a two-pixel string and the three-pixel area 116 is a three-pixelstring. In the embodiments shown, the heuristic analysis takes intoaccount such factors as the bar code elements that bound the string ofgray pixels, maximum and minimum pixel widths for the images of thenarrow bar code elements, knowledge of transition contrast between bars,and knowledge that black bars must always alternate with white bars. Forexample, the heuristic analysis shown takes into account the bar codeelements that bound the strings of gray pixels, a 1-pixel minimum widthand a 2-pixel maximum width for images of the narrow bar code elements,knowledge of transition contrast between bars, and knowledge that blackbars must always alternate with white bars. The figures illustrateembodiments of the process for 1-, 2- and 3-pixel strings, but theprinciples can be extended to longer strings.

FIG. 5A illustrates an embodiment of a process for resolving a 1-pixelgray string. The gray pixel is bounded by a leading element (LE) and atrailing element (TE). The table above the pixels illustrates thepossible combinations for LE and TE, and the corresponding resolution ofthe gray pixel. The top row of the table, for example, illustrates acase in which the LE is light (L) and the TE is dark (D). In this case,it is impossible to resolve the one-pixel gray area and it is taken tobe an extension of either the LE or the TE or both; but since it isimpossible to determine which it is, the X in the table thereforeindicates that the pixel is ignored. The third row of the tableillustrates a case in which the LE is dark (D) and the TE is also dark(D). In this case, the 1-pixel gray string can be resolved into a lightpixel.

FIG. 5B illustrates an embodiment of a process for resolving a 2-pixelgray string. As above, the 2-pixel gray string is bounded by a leadingelement (LE) and a trailing element (TE), and the table above the pixelstring illustrates the different possible combinations for LE and TE andthe corresponding resolution of the gray pixel. The top row of thetable, for example, illustrates a case in which the LE is light (L) andthe TE is dark (D). In this case, the 2-pixel gray string can beresolved into a dark pixel followed by a light pixel, because thisresult satisfies the alternation, transition contrast and minimum widthrequirements. The third row of the table illustrates a case in which theLE is light (L) and the TE is also light (L). In this case, the 2-pixelgray string can be resolved into one dark bar because this resultsatisfies the alternation, transition contrast and minimum and maximumwidth requirements for the bars.

FIG. 5C illustrates an embodiment of a process for resolving a 3-pixelgray string. As above, the 3-pixel gray string is bounded by a leadingelement (LE) and a trailing element (TE), and the table above the pixelsillustrates the different possible combinations for LE and TE and thecorresponding resolution of the 3-pixel gray string. The top row of thetable, for example, illustrates a case in which the LE is light (L) andthe TE is dark (D). In this case, the 3-pixel gray string can beresolved into a dark bar followed by a light bar because this resultssatisfies the alternation, transition contrast and minimum and maximumwidth requirements. The third row of the table illustrates a case inwhich the LE is light (L) and the TE is also light (L). In this case,the 3-pixel gray string can be resolved into a dark-light-dark (D-L-D)sequence of bars, since this is the combination that meets thealternation, transition contrast and minimum and maximum widthrequirements.

FIG. 6 illustrates an embodiment of the invention a vision system 600.The vision system 600 includes a camera 602 coupled to a decoder 608.The decoder is coupled to a non-volatile memory/storage 610 and avolatile memory 612. The camera 602 includes an image sensor 606 andfocusing optics 604 that focus an image of the bar code 104 onto thesensor 606. In one embodiment the focusing optics are refractive, but inother embodiments the focusing optics can be refractive, diffractive,reflective, or a combination of these or some subset thereof. Once theoptics 604 focus an image on the image sensor 606, the sensor captures aone- or two-dimensional image of the bar code. In one embodiment theimage sensor is a charge coupled device (CCD) array, but in otherembodiments different types of image sensors can be used.

The decoder 608 is coupled to the output of the image sensor 606 andincludes a processor to process image information received from thesensor. The decoder is also coupled to a non-volatile memory or storage610 that, among other things, stores instructions that direct thedecoder in performing its functions. In one embodiment, the memory orstorage 610 can, for example, have instruction stored thereon thatdirect the decoder to implement the processes described above inconnection with FIGS. 2, 3A-3B, 4A-4C and 5A-5C. The decoder is alsocoupled to a volatile memory 612 so that it can store and retrieve datawhile it decodes optical symbols. In the embodiment shown, the memory612 and the memory/storage 610 are shown physically separate from thedecoder, but in other embodiments one or both of the memory 612 and thememory/storage 610 can be integrated on the same unit with the decoder.Moreover, in the embodiment shown the decoder 608 is a physicallyseparate unit from the image sensor 606, although in other embodimentsthe image sensor 606 and decoder 608 can be integrated on the samedevice. The decoder can also be implemented in hardware or software.

In one embodiment of the operation of the vision system 600, the camera602 uses its optics 604 to cast an image of bar code 104 onto imagesensor 606. Image sensor 606 captures a one- or two-dimensional digitalimage of the bar code, and the digital image is transmitted to thedecoder 608. The decoder 608, in conjunction with memory 612 and usinginstructions retrieved from memory/storage 610, processes the image ofthe bar code using the processes described above in connection withFIGS. 2, 3A-3B, 4A-4C and 5A-5C.

The above description of illustrated embodiments of the invention,including what is described in the abstract, is not intended to beexhaustive or to limit the invention to the precise forms disclosed.While specific embodiments of, and examples for, the invention aredescribed herein for illustrative purposes, various equivalentmodifications are possible within the scope of the invention, as thoseskilled in the relevant art will recognize. These modifications can bemade to the invention in light of the above detailed description.

The terms used in the following claims should not be construed to limitthe invention to the specific embodiments disclosed in the specificationand the claims. Rather, the scope of the invention is to be determinedentirely by the following claims, which are to be construed inaccordance with established doctrines of claim interpretation.

1. A process comprising: computing a histogram of pixel intensity datacollected from a digital image of an optically readable symbol includinglight and dark elements of varying width; thresholding the histogram,wherein thresholding the histogram comprises: thresholding the histogramto classify individual pixels as light pixels, dark pixels or graypixels, and thresholding only the portion of the histogram correspondingto gray pixels to re-classify the gray pixels into dark pixels, lightpixels or unresolved gray pixels; and heuristically analyzing eachstring of unresolved gray pixels to determine the elements of theoptically readable symbol that created the string of unresolved graypixels.
 2. The process of claim 1, further comprising collecting pixelintensity data from one or more line scans across the digital image ofthe optically readable symbol.
 3. The process of claim 2, furthercomprising, for each pixel, averaging the intensities collected duringeach of the one or more line scans.
 4. The process of claim 1 whereinthresholding the histogram to classify individual pixels as lightpixels, dark pixels or gray pixels comprises applying a bottom-hatalgorithm to the pixel intensity data.
 5. The process of claim 1 whereinthresholding only the portion of the histogram corresponding to graypixels comprises applying a bottom-hat algorithm to the gray pixelintensity data.
 6. The process of claim 1 wherein analyzing each stringof unresolved gray pixels heuristically comprises analyzing each stringbased on the number of pixels in the string and the symbol elementsbounding the string.
 7. The process of claim 6 wherein the heuristicanalysis is further based on minimum and maximum widths, measured inpixels, of the images of the elements of the optically readable symbol.8. The process of claim 7 wherein the minimum narrow element width isapproximately between 1 pixel and 2 pixels.
 9. An apparatus comprising:a decoder including a processor programmed with instructions to: computea histogram of pixel intensity data collected from a digital image of anoptically readable symbol including light and dark elements of varyingwidths; threshold the histogram to classify individual pixels as lightpixels, dark pixels or gray pixels, and threshold only the portion ofthe histogram corresponding to gray pixels to re-classify the graypixels into dark pixels, light pixels or unresolved gray pixels; andheuristically analyze each string of unresolved gray pixels to determinethe elements of the optically readable symbol that created the string ofunresolved gray pixels.
 10. The apparatus of claim 9 wherein theprocessor is further programmed with instructions to collect pixelintensity data from one or more line scans across the digital image ofthe optically readable symbol.
 11. The apparatus of claim 10, whereinthe processor is further programmed with instructions to, for eachpixel, average the intensities collected during each of the one or moreline scans.
 12. The apparatus of claim 9 wherein the instructions tothreshold the histogram to classify individual pixels as light pixels,dark pixels or gray pixels comprise instructions to apply a bottom-hatalgorithm to the pixel intensity data.
 13. The apparatus of claim 9wherein the instructions to threshold only the portion of the histogramcorresponding to gray pixels comprise instructions to apply a bottom-hatalgorithm to the gray pixel intensity data.
 14. The apparatus of claim 9wherein the instructions to heuristically analyze each string ofunresolved gray pixels comprise instructions to analyze each string ofunresolved gray pixels based on the number of pixels in the string andthe symbol elements bounding the string.
 15. The apparatus of claim 14wherein the instructions to heuristically analyze each string ofunresolved gray pixels further comprise instructions to analyze eachstring of unresolved gray pixels based on minimum and maximum widths,measured in pixels, of the images of narrow elements of the opticallyreadable symbol.
 16. The apparatus of claim 15 wherein the minimumnarrow element width is approximately between 1 pixel and 2 pixels. 17.A system comprising: a camera to capture a digital image of an opticallyreadable symbol, wherein the optically readable symbol includes lightelements and dark elements of varying widths; a decoder coupled to thecamera; a storage or memory coupled to the decoder, the storage ormemory having stored thereon instructions that, when executed by thedecoder, cause the decoder to: compute a histogram of pixel intensitydata collected from a digital image of an optically readable symbolincluding light and dark elements; threshold the histogram to classifyindividual pixels as light pixels, dark pixels or gray pixels, andthreshold only the portion of the histogram corresponding to gray pixelsto re-classify the gray pixels into dark pixels, light pixels orunresolved gray pixels; and heuristically analyze each string ofunresolved gray pixels to determine the elements of the opticallyreadable symbol that created the string of unresolved gray pixels. 18.The system of claim 17 wherein the instructions further includeinstructions to collect pixel intensity data from one or more line scansacross the digital image of the optically readable symbol.
 19. Thesystem of claim 18, wherein the instructions further includeinstructions to, for each pixel, average the intensities collectedduring each of the one or more line scans.
 20. The system of claim 17wherein the instructions to threshold the histogram to classifyindividual pixels as light pixels, dark pixels or gray pixels compriseinstructions to apply a bottom-hat algorithm to the pixel intensitydata.
 21. The system of claim 17 wherein the instructions to thresholdonly the portion of the histogram corresponding to gray pixels compriseinstructions to apply a bottom-hat algorithm to the gray pixel intensitydata.
 22. The system of claim 17 wherein the instructions toheuristically analyze each string of unresolved gray pixels compriseinstructions to analyze each string of unresolved gray pixels based onthe number of pixels in the string and the symbol elements bounding thestring.
 23. The system of claim 22 wherein the instructions toheuristically analyze each string of unresolved gray pixels furthercomprise instructions to analyze each string of unresolved gray pixelsbased on minimum and maximum widths, measured in pixels, of the imagesof the elements of the optically readable symbol.
 24. The system ofclaim 17 wherein the minimum narrow element width is approximatelybetween 1 pixel and 2 pixels.